Hanger bar centering mechanism

ABSTRACT

A hanger bar centering mechanism comprises a first elongate member having a first end and a second end, a second elongate member having a first end and a second end, the first and second members are symmetrically formed, the first and second elongate members each have at least one corresponding notch portion, and the notch portions are aligned for providing positive feedback when the first and second members are slidably positioned relative to each other in a preselected specific position.

CROSS REFERENCES TO RELATED APPLICATIONS

None.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

None.

REFERENCE TO SEQUENTIAL LISTING, ETC.

None.

BACKGROUND

1. Field of the Invention

The present invention provides a centering mechanism for a recesseddownlight frame-in kit. More specifically, the present inventioncomprises a hanger bar centering mechanism for a recessed downlightframe-in kit.

2. Description of the Related Art

Recessed downlight fixtures have become increasingly popular forresidential and commercial use. One reason for the increased popularityis that the recessed downlight fixtures meet a wide range of interiorlighting requirements while also being aesthetically pleasing. Furtherthese recessed downlight fixtures may be installed in new constructionsas well as existing ceilings and therefore are liked by installers.Typically, ceiling-mounted recessed downlight fixtures comprise a frameor frame-in kit with means for securing the frame to structural supportsof the ceiling. For installation, the frame of the light fixture mayinclude holes or brackets through which fasteners are used to positionand attach the fixture to the supports.

One difficulty associated with the installation of recessed lightingframe-in kits is the positioning of the frame-in kit in a centeredposition between joists or suspended ceiling members quickly in arepetitive and consistent manner. For example, when one light in a rowof recessed lights is out of alignment, the installation looks poor inquality and is undesirable for a customer. In suspended ceilings it ispreferable to have the lights centered in two dimensions so that thelight fixture is centered within a block of the suspended ceiling. Theresult is an aesthetically pleasing installation which is time consumingand difficult to obtain consistently.

One facet in solving this problem is that in many applications distancesbetween ceiling joists or suspended ceiling members are consistent. Forexample, most ceiling joists or suspended ceiling members may be spacedapart on two feet (24 inch) centers. Building codes within geographicregions typically dictate such distances. Since such span betweenmembers is known and is consistently used in many constructions, itwould be helpful for installers to utilize a mechanism to quickly andconsistently center the recessed downlight fixture between ceilingmembers to provide an aesthetically pleasing installation.

Thus there is a need for a positioning mechanism, for example, acentering mechanism which provides positive feedback to an installer andmay be utilized quickly and consistently with frame-in kits forcentering light fixtures during lighting installations.

SUMMARY OF THE INVENTION

According to a first embodiment of the present invention, a hanger barcentering mechanism comprises a first elongate member having a first endand a second end, a second elongate member having a first end and asecond end, the first and second members are symmetrically formed, thefirst and second elongate members each have at least one correspondingnotch portion, and the notch portions are aligned for providing positivefeedback when the first and second members are slidably positionedrelative to each other in a preselected specific position.

The first and second elongate members each have a first notch portionand a second notch portion. The longitudinal edge of the elongate memberhas an upper notch portion and a lower notch portion disposed on upperand lower edges, respectively of the first and second elongate members.The first and second symmetrical elongate members may be channel shapedor may be substantially v-shaped.

The mounting plate is movable from a first longitudinally alignedposition to a second non-aligned position. The mounting plates arelocated at one of the first end and the second end of the first andsecond elongate members.

The hanger bar centering mechanism may further comprise a clip mechanismretaining the first and second elongate members in sliding engagementand locking the first and second elongate members in a centeredposition. The clip mechanism and the notch portions also providespositive feedback to an installer that the first and second elongatemembers are disposed in the preselected position.

According to a second embodiment, a hanger bar centering mechanismcomprises a clip mechanism having at least one preselected dimension,first and second channels slidably positioned adjacent the clipmechanism, the first and second channels each have at least one notch ofthe preselected dimension, the at least one notch receiving the clipmechanism when the first and second channels are in a preselectedposition.

The hanger bar centering mechanism further comprises a mounting plate atone end of each of the first and second channels. The at least one notchand the clip mechanism operably engage and provide positive feedback toan installer that first and second channels are disposed in a centeredposition. The clip mechanism slidably retains said first and secondchannels in a centered position. The clip mechanism locks the first andsecond channels in the centered position.

According to a third embodiment, a hanger bar locking mechanismcomprises a first elongate member slidably abutting a second elongatemember, the first and second elongate members both have one of a malepart and a female part, a clip mechanism defines the other of a malepart and a female part, the clip mechanism engages the first and secondelongate members when the first and second elongate members are in acentered position, the ring aperture is centrally located between endsof the first and second elongate members.

According to a fourth embodiment, a hanger bar locking mechanismcomprises a first elongate member of a first preselected length having amale portion, a second elongate member of a second preselected lengthhas a female portion, the first elongate member slidably engages thesecond elongate member, the male portion engages said female portionwhen the first elongate member and the second elongate member arepositioned for a specific spacing between ceiling members. The first andsecond preselected lengths may be equal or unequal. The device mayfurther comprise a clip mechanism to retain the first and second membersin the centered position.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a perspective view of a recessed downlight frame-in kit;

FIG. 2 depicts a perspective view of a single hanger bar;

FIG. 3 depicts a perspective view of two hanger bars slidably positionedagainst one another;

FIG. 4 depicts a perspective view of the two hanger bars of FIG. 3 withnotches aligned for centering of the frame-in kit of FIG. 1;

FIG. 5 depicts a close-up perspective view of the hanger bars andfastening mechanism;

FIG. 6 depicts a first alternative embodiment of the hanger barcentering mechanism;

FIG. 7 depicts a second alternative embodiment of the hanger barcentering mechanism;

FIG. 8 depicts a clip for use with the second alternative embodiment ofFIG. 7;

FIG. 9 depicts a third alternative embodiment of the hanger barcentering mechanism; and,

FIG. 10 depicts a fourth alternative embodiment of the hanger barcentering mechanism.

DETAILED DESCRIPTION

It should be understood that the invention is not limited in itsapplication to the details of construction and the arrangement ofcomponents set forth in the following description or illustrated in thedrawings. The invention is capable of other embodiments and of beingpracticed or of being carried out in various ways. Also, it is to beunderstood that the phraseology and terminology used herein is for thepurpose of description and should not be regarded as limiting. The useof “including,” “comprising,” or “having” and variations thereof hereinis meant to encompass the items listed thereafter and equivalentsthereof as well as additional items. Unless limited otherwise, the terms“connected,” “coupled,” and “mounted,” and variations thereof herein areused broadly and encompass direct and indirect connections, couplings,and mountings. In addition, the terms “connected” and “coupled” andvariations thereof are not restricted to physical or mechanicalconnections or couplings. Furthermore, and as described in subsequentparagraphs, the specific mechanical configurations illustrated in thedrawings are intended to exemplify embodiments of the invention however,other alternative mechanical configurations are possible which areconsidered to be within the teachings of the instant disclosure.

Referring initially to FIG. 1, a frame-in kit or plaster frame 10 isshown in perspective view. The frame-in kit 10 is typically installed inceilings or suspended ceiling installations. The frame-in kit 10 definesa location for housing recessed lighting components. The frame-in kit 10comprises a junction box 12 wherein wire splices may be disposed forelectrical communication between a ballast (not shown) and a lightsource or lamp, such as an HID lamp (not shown). The junction box 12comprises a top wall 17, a bottom wall 18, and opposed side walls 20 topartially define the junction box and front and rear openings. Thebottom wall 18 is substantially rectangular in shape and contains aplurality of door tab apertures 19.

The junction box 12 further comprises front and rear junction box doors(not shown) which are substantially square in shape but may berectangular or some other geometry according to the shape of thejunction box openings. The doors also each have at least one tabextending from a lower edge thereof. The tabs are positioned within tabapertures 19 in the bottom wall 18 of the junction box 12 so that thedoors extend upwardly from the bottom wall closing the front and rearopenings. At the upper wall 17, the front and rear doors (not shown) areretained in place by a door arm 16. The door arm 16 has an aperturetherein which is aligned with a fastening aperture in the top wall 17. Afastener, for instance a rivet or screw, is positioned through thefastening apertures to retain the door arm 16.

Referring still to FIG. 1, the sidewalls 20 and the upper wall 17 eachmay have at least one knockout 14 therein to provide a plurality ofpaths for electrical wires and conduit to move from within the junctionbox 20 to the lamp housing 12 as well as a plurality of knock-outs 14for entry of wiring into the junction box 12.

Extending from an edge of the junction box 12 are frame arms 22, 24. Theframe arms 22, 24 are spaced apart a preselected diameter based on afixture ring 26 being used. The exemplary fixture ring 26 is circular inshape having a sidewall and an upper shoulder and receives the fixture,light source and other components within the ceiling wherein theframe-in kit 10 is positioned. Since a fixture assembly (not shown) maycomprise alternative sizes and shapes, the fixture ring 26 isappropriately sized for the fixture used and the frame arms 22,24 aresized to receive the ring 26. The frame arms 22,24 are connected to thefixture ring 26 by fastener or alternative means of connection. Clipmechanisms 40 are operably connected to the upper shoulder of thefixture ring 26 in diametrically opposed positions and therefore arealigned with the center of the aperture ring 26. The clip mechanisms 40will be discussed further hereinafter.

Referring still to FIG. 1, extending through the clip mechanisms 40 arehanger bars 50 specifically, two hanger bars 50 are slideably disposedthrough each clip mechanism 40. The hanger bars 50 are extending throughthe clip mechanisms 40 in a parallel arrangement for installation of theframe-in kit 10 between two ceiling members. Typically the frame-in kit10 is arranged so that the hanger bars 50 extend transversely relativeto parallel structural ceiling members.

Referring now to FIG. 2, a single hanger bar 50 is shown in perspectiveview. The hanger bar 50 is an elongate member having a first end 52 anda second end 54. The hanger bar 50 is substantially V-shaped and, asshown, has an upper leg 56 and a lower leg 58 which define the V-shapedchannel or beam. However, it should be understood by one of ordinaryskill in the art that alternative shapes and structures may be utilizedwhich, when placed together as shown and described herein, sliderelative to one another without substantial interference. The hanger bar50 comprises an upper notch 60 and a lower notch 62 which operablyengage portions of the clip mechanism 40. The upper and lower notches60, 62 are positioned on the hanger bar 50 such that when the notches60,62 are aligned and engage the clip mechanisms 40 (FIG. 1), the secondends 54 of each hanger bar 50 extend an equal distance from the centerof the fixture ring 26. Accordingly, such construction allows for theinstallation of the framing kit 10 in such a manner that the fixturering 26 is centered between ceiling members in a centered position.Alternatively, the bars 50 may be formed so that when the notches 60, 62are aligned the ring 26 is at some pre-selected position for variousinstallation scenarios. The upper and lower notches 60, 62 are utilizedso that the hanger bars 50 are symmetrical in shape. Thus a singlehanger bar 50 may be manufactured and utilized for mounting the frame-inkit 10 rather than requiring the manufacture of multiple hanger bars foruse with a single assembly. The upper and lower notches 60, 62 aresubstantially U-shaped and are defined by 90° (degrees) angles formingthe notched portions of the longitudinal edges of the hanger bar 50. Theangles defining the upper and lower notches 60, 62 may vary butaccording to one exemplary embodiment are about 90°. Such angle providesthe user with positive feedback and a definitive snapping feel when theclip mechanism 40 engages the notches 60, 62.

At a second end 54 of the hanger bar 50 is a mounting plate 70 which isconnected to the elongate portion of hanger bar 50 by a neck 72. Themounting plate 70 further comprises a fastening aperture 74 throughwhich a fastener may be connected to a joist to retain the hanger bar 50in position relative to the member. The mounting plate 70 may be foldedat the neck 72 such that the plate is perpendicular to the longitudinalaxis of the hanger bar 50 and parallel to an adjacent ceiling member inorder to properly fasten the mounting plate 70 to the ceiling member.

Referring now to FIG. 3, the hanger bars 50 are shown in perspectiveview and positioned relative to one another for sliding movement. Thechannel shapes of the elongate members provide for adjacent positioningand for sliding motion of the hanger bars 50 relative to one another andrelative to the clip mechanism 40 (FIG. 1). The hanger bars 50 are shownin a position such that the upper and lower notches 60, 62 of eachhanger bar 50 are not aligned. To align the notched 60,62 the bars 50are moved longitudinally so that the notches are aligned.

Referring now to FIG. 4, the hanger bars 50 are shown with the upper andlower notches 60, 62 aligned as would be the case when the clipmechanism 40 engages both adjacent hanger bars 50. The clip mechanism 40is removed to clearly depict the alignment of the upper and lowernotches 60, 62. When the notches 60,62 are aligned and engaging the clipmechanism 40, the ring 26 is in a preselected specific position, forexample the centered position.

Referring now to FIG. 5, the clip mechanism 40 is shown retaining thehanger bars 50 in position. The clip mechanism 40 comprises a C-shapedclip portion 42, the clip portion 42 comprises upper and lowerhorizontal surfaces and a vertical surface extending between the upperand lower vertical surfaces defining the C-shape and further defining aposition for retaining the hanger bars 50. The lower horizontal surfaceof the clip portion 42 comprises a clasp aperture 44 for receiving a tabfrom a clasp 46. Although the clip portion 42 is shown as C-shaped,various alternative geometries may be utilized to retain the hanger bars50 in position. As depicted in the figure, the edges of the clip portion42 engage the notched portions 60, 62 of the hanger bars 50. The clasp46 comprises a metal strap having four edges and a tab 48 depending froma lowermost edge of the clasp 46. The tab 48 extends through the claspaperture 44 of the clip portion 42 to inhibit movement of the clasp 46away from the C-shaped clip portion 42. The clasp 46 also has a bulgedportion 49 opposite the vertical surface of the clip portion 42. Thebulged portion of clasp 46 also provides for positioning of the hangerbars 50 between the clip portion 42 and clasp 46. At the upper end ofthe clasp 46 is a threaded fastener which may be tightened with a wingnut as shown in FIG. 1 to tighten the clasp 46 and provide some verticaladjustment feature.

Referring now to FIGS. 6-10, various alternative embodiments of thehanger bar centering mechanism are depicted in perspective view.Referring first to FIG. 6, first and second slideably positionedchannels or bars 150 are depicted. The channels are adjacent one anotherand disposed so as to slide longitudinally relative to one another asdescribed previously. The structural shape allows the bars to bepositioned slidably adjacent one another. The bars 150 are symmetricallyshaped so that a single bar design may be utilized for the right handand left hand sides of the frame-in kit (FIG. 1). The bars 150 furthercomprise apertures 151 which become aligned when the bars 150 arepositioned to fit between ceiling members of a preselected spacing. Forexample, the members may be on 16 inch centers or alternatively on 24inch centers as building codes differ within different geographicregions and the hanger bars 150 may be manufactured for use within thesedistances. The aperture 151 receives a rod 153 so that the rod 153extends through both of the hanger bars 150 and locks the hanger bars150 in a position to be disposed between the pre-selected ceiling memberspacing. Otherwise stated, the symmetrical hanger bars 150 comprisefemale parts 151 which receive a male part 153 extending through bothhanger bars 150 to lock the hanger bars in the pre-selected spacialposition. It should be understood that the hanger bars may bemanufactured to various pre-selected lengths corresponding to theon-center distance of suspended ceiling member or joists or may bemanufactured so that the aperture ring is disposed at some otherpre-selected position.

Referring now to FIG. 7, an alternative embodiment of the hanger barcentering mechanism is shown. The embodiment depicted in FIG. 7comprises two slidably adjustable channels having structural geometryallowing longitudinal slidable motion relative to one another. The firstchannel 250 is an elongate member having a boss 251 extending from thatelongate member. The second channel 252 is also an elongate memberhaving a similar geometric or structural shape to allow sliding motionrelative to the first channel 250. The second channel 252 furthercomprises an aperture 253 which receives the boss 251 of the firstchannel 250. When the boss 251 and the aperture 253 are aligned thelengths of the first and second channels 250, 252 are positioned so thatthe channels 250, 252 extend between ceiling members of a pre-selectedcenter distance.

Referring now to FIG. 8, a portion of the clip mechanism 40 is shown.The clasp 146 is shown having an aperture 147 in the bulged portion 149.The aperture 147 receives the boss 251 which is extending through theaperture of the second channel 252 in order to retain the hanger bars250, 252 in the appropriate position relative to the other portions ofthe frame-in kit 10.

As shown in FIG. 9, an alternative assembly of hanger bars 350, 352 isshown. The first hanger bar 350 is substantially L-shaped. The secondhanger bar 352 comprises a C-shaped channel structure which receives theL-shaped first hanger bar 350. Alternatively, the L-shaped first hangerbar 350 may also be C-shaped and sized to fit within the web portion ofthe second hanger bar 352. Thus, such design allows the first hanger bar350 to slide relative to second hanger bar 352. The bars 350, 352 may belocked for a pre-selected specific position by many of the structurestaught herein including male-female portions, notches, or otherequivalent structures which lockably engage upon reaching thepre-selected position.

Referring now to FIG. 10, an alternative structural embodiment isdepicted for the channels. According to the embodiment of FIG. 10, bothelongate members 450 are substantially L-shaped wherein one leg isshorter than the second leg allowing the elongate members to sliderelative to one another. It should be understood by one of ordinaryskill in the art that the various notches, male and female parts orbosses and apertures may be utilized with various structural shapestaught throughout the various embodiments described in the instantdisclosure.

In operation, two hanger bars 150 are inserted through and captured byend clip mechanism 40. The clip mechanism 40 is tightened so that thepair of hanger bars 150 are captured within each clip mechanism 40 butare slidable. Next the hanger bars 150 are pulled apart or pushedtogether longitudinally by the ends having the mounting plates 70 untilthe notches 60, 62 are aligned. As the hanger bars 150 are pulled apart,the notches 60,62 will each engage the clip mechanism 40, eitherseparately or simultaneously. Once the notches 60,62 are engaging theclip mechanism 40, the clip mechanism may be tightened further, ifnecessary. According to other embodiments described herein, when thehanger bars are aligned male and female parts engage one another.

The foregoing description of several methods and an embodiment of theinvention has been presented for purposes of illustration. It is notintended to be exhaustive or to limit the invention to the precise stepsand/or forms disclosed, and obviously many modifications and variationsare possible in light of the above teaching. It is intended that thescope of the invention be defined by the claims appended hereto.

1. A hanger bar centering mechanism, comprising: a first elongate memberhaving a first end and a second end; a second elongate member having afirst end and a second end; said first and second members beingsymmetrically formed; said first and second elongate members each havingat least one corresponding notch portion; said notch portions beingaligned for providing positive feedback when said first and secondmembers are slidably positioned relative to each other in a preselectedspecific position.
 2. The hanger bar of claim 1, said first and secondelongate members each having a first notch portion and a second notchportion.
 3. The hanger bar of claim 1, said longitudinal edge of saidelongate member having an upper notch portion and a lower notch portiondisposed on upper and lower edges, respectively of said first and secondelongate members.
 4. The hanger bar of claim 1, said mounting platebeing movable from a first longitudinally aligned position to a secondnon-aligned position.
 5. The hanger bar of claim 1 further comprising amounting plate at one of said first end and said second end of saidfirst and second elongate members.
 6. The hanger bar of claim 1, saidfirst and second symmetrical elongate members being channel shaped. 7.The hanger bar of claim 1, said first and second symmetrical elongatemembers being substantially v-shaped.
 8. The hanger bar of claim 1further comprising a clip mechanism retaining said first and secondelongate members in sliding engagement and locking said first and secondelongate members in a centered position.
 9. The hanger bar of claim 1,said clip mechanism and said notch portions locking and providingpositive feedback to an installer that said first and second elongatemembers are disposed in said preselected position.
 10. A hanger barcentering mechanism, comprising: a clip mechanism having at least onepreselected dimension; first and second channels slidably positionedadjacent said clip mechanism; said first and second channels each havingat least one notch of said preselected dimension; said at least onenotch receiving said clip mechanism when said first and second channelsare in a preselected position for mounting.
 11. The hanger bar centeringmechanism of claim 10 further comprising a mounting plate at one end ofeach of said first and second channels.
 12. The hanger bar centeringmechanism of claim 11, said at least one notch and said clip mechanismoperably engaging and providing positive feedback to an installer thatfirst and second channels are disposed in a centered position.
 13. Thehanger bar centering mechanism of claim 10, said clip mechanismretaining said first and second channels in a centered position.
 14. Thehanger bar mechanism of claim 13, said clip mechanism locking said firstand second channels in said centered position.
 15. A hanger bar lockingmechanism, comprising: a first elongate member slidably abutting asecond elongate member; said first and second elongate members bothhaving one of a male part and a female part; a clip mechanism definingthe other of a male part and a female part; said clip mechanism engagingsaid first and second elongate members when said first and secondelongate members are in a centered position; said ring aperturecentrally located between ends of said first and second elongatemembers.
 16. A hanger bar locking mechanism, comprising: a firstelongate member of a first preselected length having a male portion; asecond elongate member of a second preselected length having a femaleportion; said first elongate member slidably engaging said secondelongate member; said male portion engaging said female portion whensaid first elongate member and said second elongate member arepositioned for a specific spacing between ceiling members.
 17. Thehanger bar locking mechanism of claim 16 wherein said first and secondpreselected lengths are equal.
 18. The hanger bar locking mechanism ofclaim 16 wherein said first and second preselected lengths are notequal.
 19. The hanger bar locking mechanism of claim 16 furthercomprising a clip mechanism to retain said first and second members insaid centered position.